A gear wheel is a visual tool for optimizing the set-up process in manufacturing. It is designed to help manufacturing companies reduce the time and effort required to switch from one product to another.
A gear wheel is usually a circular diagram divided into segments, each segment representing a different product to be manufactured. The segments are arranged in the most cost-efficient order for carrying out the set-up process, with the aim of reducing the time required to switch from one product to another.
The gear wheel is therefore a setup matrix which shows the optimal sequence path through the matrix.
Gear wheel to reduce overall set-up costs
The key advantage of using a gear wheel is that it improves OEE. By streamlining the set-up sequence, manufacturers can reduce the time and effort required to switch from one production run to another. This helps to increase the overall speed of your plant and produce more products in less time.
It is important to note that the reduction of set-up times results from the clever combination of production orders, not from the optimization of the actual set-up process. This optimization would be part of the SMED concept — Single Minute Exchange of Dies.
Overall, the use of a gear wheel is a valuable tool for manufacturers who want to optimize their production processes. By streamlining the set-up process and reducing the time and effort required to switch from one product to another, manufacturers can improve efficiency, reduce costs, and increase overall profitability.
Gear wheel as an element of interval production
The gear wheel is part of a larger concept of interval production. In interval production, a defined production program — or a selection of it — is executed in the same order over and over again. This form of production is often supported by Kanban and supermarkets.
An important key figure in this context is the so-called EPEI — Every Part Every Interval. This key figure indicates the time it takes at the system to get back to the first product, i.e. to go through the cycle once.
oee.ai supports the creation of the setup wheel by precisely recording the set-up times of all variants, which is materialized in a setup matrix in the first step. The data from this setup matrix can be transmitted to the planning system in real time via an API, so that planning is always carried out with current and optimal data.
Do you have any questions about the gear wheel or the gear matrix? Then feel free to contact us.